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Metoda brzog projektiranja ljevačkog panela za ubrizgavanje plastičnog zupčanika
M. Ogrizovic, G. Dudukovic
ISSN 1330-3651
UDC/UDK 621.81.01:004.42 ProEngineer
THE TECHNIQUE OF QUICK DESIGNING OF CASTING PANEL
FOR PLASTIC GEAR WHEEL INJECTION
Milutin Ogrizovic, Goran Dudukovic
Professional paper
The current technological level of mechanical engineering sequentially requires an active software application in all construction stages of certain mechanical
projects – products. When we say product today in engineering we refer to the design of a product, as well as to the actual construction. ProEngineer, as basic
software of this thesis, with its interactively connected modules, is a completely functional tool for solving even the most complex tasks of mechanical
engineering in acceptable time frame. The notion of acceptable construction time frame and mechanical design production includes problem solving aiming at
constructing the final product, in any shape, tending to optimize all stages of planning, analysis, development and production. The speed of construction task
solving conditions the existence of profitable production in mechanical engineering, which should be proved through the work under this title. It is said
previously that the foundation of this thesis is the application of interactively joined software modules for constructing a casting panel for injected plastic gear
wheel.
Keywords: casting panel, interactive connected modules, plastic gear wheels, Pro/Engineer
Metoda brzog projektiranja ljevačkog panela za ubrizgavanje plastičnog zupčanika
Strukovni članak
Sadašnji tehnološki nivo strojarstva zahtijeva aktivnu primjenu softvera u svim stadijima izrade nekog strojarskog projekta – proizvoda. Izraz proizvod u
strojarstvu se danas odnosi i na projektiranje i na stvarnu izradu tog proizvoda. ProEngineer, kao osnovni softver ovoga rada je, sa svojim interaktivno
povezanim modulima, potpuno funkcionalan alat za rješavanje i najsloženijih strojarskih zadataka u prihvatljivom vremenskom razmaku. Pojam prihvatljivog
vremena proizvodnje i izrade proizvoda uključuje rješavanje problema s ciljem dobivanja finalnog proizvoda, bilo kojeg oblika, uz optimiziranje svih stadija
planiranja, analize, razvoja i proizvodnje. Brzina rješavanja konstrukcijskog zadatka je uvjet postojanja profitabilne proizvodnje u strojarstvu, a ovaj bi rad to
trebao dokazati. Ranije je rečeno da je ovaj rad zasnovan na primjeni interaktivno povezanih modula softvera za konstruiranje ljevačkog panela za ubrizgani
plastični zupčanik.
Ključne riječi: interaktivno spojeni moduli, ljevački panel, plastični zupčanik, Pro/Engineer
1
Introduction
Uvod
The basic task, within the theme framework of this
thesis, is to produce a tool within a short space of time, and
then place the cast gear wheels in gauge set and conduct the
tests. The strategy for solving this particular construction
task was clear: establish a new calculation model for the
gear wheel tooth evolute in the program calculation module
– MathCad, and as a result choose 15 interpolation points in
Cartesian coordinate system. These points represent the
basis for creating 3D gear wheel models, through
application of special module program tools "Part",
properties similar to the presupposed ones. The simulation
analysis in this module provides the necessary parameters
"Blend", or "Swept Blend". This combines the direct
interactive software connection of two program modules,
with the automatic correction possibility of any
computation parameter. The choice of the gear wheel
material in "Plastic Advisor" module, as well as the choice
of potential casting system position can help in detecting
places where cracks, air pockets or thickness variation
might appear. The work in the said module is extremely
functional, because of the existence of a vast material data
base of various manufacturers and material properties, so
the change of any parameter yields immediate results, but
also suggests the best and most precise material with the
Figure 1 The calculation in MathCad and the results obtained for the evolute calculation in 15 points
Slika 1. Proračun u MathCadu i rezultati za proračun evolvente u 15 točaka
Technical Gazette 17, 2(2010), 251-254
251
M. Ogrizovic, G. Dudukovic
The technique of quick designing of casting panel for plastic gear wheel injection
Figure 2 Important points in "Part" module
Slika 2. Važne točke u modulu "Part"
Figure 3 3D gear wheel model
Slika 3. 3D model zupčanika
Figure 4 Mold temperature, Melting temperature, Injection time, Max. injection pressure, Flow rate. The stated results have been
obtained based on the dimensions of the gear wheel, i.e. the chosen place for the injecting nozzle
Slika 4. Temperatura kalupljenja, Temperatura taljenja, Vrijeme ubrizgavanja, Maksimalni tlak ubrizgavanja, protok.
Rezultati su dobiveni na osnovu dimenzija zupčanika tj. izabranog mjesta mlaznice za ubrizgavanje
for the injection machine, which is of extreme importance
for obtaining predesigned product quality – gear wheel. In
the end, by choosing optimum technological sequence
parameters in program module "Manufacturing", a direct
steering file is created for the specific CNC milling machine
on which injection tool casting panels are manufactured.
2.1
The choice of the material, casting point, casting
quality analysis and casting panel designing
Izbor materijala, točka lijevanja, analiza kvalitete lijevanja i
projektiranje ljevačkog panela
2
Modelling, gear wheel casting process simulation and
creation of steering file for casting panel
manufacturing
Modeliranje, simulacija postupka lijevanja zupčanika i
kreiranje datoteke za pokretanje proizvodnje ljevačkih
panela
The designed gear wheel model, by simple activation of
"Plastic Advisor" module, becomes available for analysis
defining the shape and position of tool casting panel,
determines the casting place (nozzle), tool temperature, the
optimum flow of plastics through the nozzle, i.e.
recommends injection machine property in view of the
required injection pressure (Fig. 4). All parameters obtained
are set according to the properties of the chosen plastic
material (BASF Luran 358 N).
The material choice from the program data base is
highly functional, because every material has the defined
general mechanical properties, as well as the specific ones
like the shearing module (Shear module), which provides
absolutely reliable goal parameters (transmission ratio) to
those required. Besides the general mechanical properties,
within material data base framework specific data like
mechanical properties of material behaviour at certain
temperatures (Thermal properties) are available, i.e. the
surface area condition - the key condition for functional
The interactive engineering element modelling with
combined software tools has a 3D model as a base. The 3D
gear wheel model designed according to the chosen
calculation parameters of cam wheel profile evolute enables
swift tool designing and gear wheel casting. The results of
cam wheel profile evolute calculation in MathCad (Fig. 1)
are inserted in module "Part" (Fig. 2), which represents the
base for the application of "Blend" program tool creating the
gear wheel model, as well as the gear wheel final model
(Fig. 3).
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Tehnički vjesnik 17, 2(2010), 251-254
M. Ogrizovic, G. Dudukovic
Metoda brzog projektiranja ljevačkog panela za ubrizgavanje plastičnog zupčanika
work of plastic gear wheels under the specific work regimes
(Fig. 5).
In "Plastic Advisor" module it is possible to check,
besides the mentioned parameters, the places of potential
cracks, air pockets, as well as the condition of the surface
layer. This completes the analysis of the potential casting.
The shrinkage percentage can be adopted (Shrinkage by
scale) due to which the model must be enlarged before
designing the casting panel (Fig. 6).
Figure 5 Chosen material mechanical properties palette
Slika 5. Paleta mehaničkih svojstava izabranog materijala
Figure 6 The adopted "shrinkage" percentage of plastics based on which the final casting panel model was created
Slika 6. Prihvaćeni postotak "stezanja" plastike na osnovu kojega je stvoren završni model ljevačkog panela
Figure 7 The presented part of the G-code of the direct steering file
Slika 7. Predstavljeni dio G-koda direktne upravljačke datoteke
Technical Gazette 17, 2(2010), 251-254
253
Tthe technique of quick designing of casting panel for plastic gear wheel injection
M. Ogrizovic, G. Dudukovic
Figure 8 Total machining time of the casting panel and individual time in a technological sequence
Slika 8. Ukupno vrijeme izrade ljevačkog panela i pojedinačno vrijeme u tehnološkom nizu
2.2
Designing of casting panel
Projektiranje ljevačkog panela
enabled a sustainable production, because we were ahead of
our competitors in quality and production time, in the
example presented.
The final task is the creating of the direct steering file in
NC "Manufacturing" module for particularly chosen
machine (milling machine – Mill) on which the casting
panel is manufactured. Other tool elements are adopted
through recommendation of the chosen manufacturer of
standard parts – tool elements "HASCO". The adopted
standard tool parts (and casting system), are implemented to
the software on the level of module-parts in the functional
assembly position. Thus it leaves us with creating the
technological machining sequences for casting panel,
according to the standard manufacturer recommendation,
and the later post-processing i.e. creating the direct steering
file (.tap files) through which on the level of G-code the
direct operating of the chosen CNC machine is performed
(Fig. 7).
4
List of symbols
Popis simbola
3
Conclusion
Zaključak
The thesis shows the procedure of obtaining –
designing tool casting panel for injecting of plastic gear
wheels, from the gear wheel tooth evolute calculation stage,
through designing the gear wheel 3D model, and then the
casting panel, to creating technological machining
sequences i.e. steering file (.tap file) for designing the
casting panel on triaxial CNC milling machine.
Besides the description of particular procedures
through all designing stages, the concept of time
significance, in which the tool plate is obtained i.e. the
beginning of production time, is interwoven in the thesis.
The aim is to represent, through an example, the
possibilities of interactively connected ProEngineer
software modules, i.e. benefits gained through their use.
From the beginning of designing to the gear wheel
production seven days elapsed, taking into account the
ordering of standard tool parts from the "HASCO"
company. The tool test series lasted also seven days, after
which production output began. The presented timeline has
254
Standard gear wheel module mn, mm
Gear wheel teeth number z
The helix inclination angle β, deg (°)
Gear wheel width b, mm
The number of evolute points n
Casting panel temperature Mold temp, degC (°)
Cast temperature Melt temp, degC (°)
Injection time Inj. time, s
Injection pressure maximum Max. inj. pres., MPa
Cast flow Flow rate, m3/s
Elasticity module E, MPa
Machining time Machin. Time, min.
5
References
Literatura
[1] Ogrizović, M. Interaktivno modeliranje mašinskih
konstrukcija u praksi. // Kompjuter biblioteka : Beograd,
2002.
[2] Ogrizović M. Upravljanje CNC mašinama iz ProEngineera
Wildfire. // Kompjuter biblioteka : Beograd, 2008.
[3] Vračević, M. Prerada plastičnih masa brizganjem. // POLIbiblioteka : Novi Sad, 1997.
[4] Perošević, B. Kalupi za injekciono presovanje plastomeratermoplasta. // Naučna knjiga : Beograd, 1995.
Authors' addresses
Adrese autora
Milutin Ogrizović
Tehnička škola, Stara Pazova, Vojvodina, Srbija
Goran Duduković
SOLFINS, CAD/CAM Company, Beograd, Srbija
Tehnički vjesnik 17, 2(2010), 241-254

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